Cracked manifold.

- Carnesville, GA, USA

Found crack in exhaust manifold between the #1 and #2 ports at around 68,000 miles, after discussing this problem with a number of other Jeep owners I learned this is a common problem with the 1999 and other years back. My complaint is, if daimler Chrysler is aware of this problem and I am sure they are, why aren't they addressing it. Unhappy with dealer and stock manifold, replaced with after market exhaust manifold header.

- Bakersfield, CA, USA

I took my Jeep to chuck nash Jeep because of a popping sound. They said the exhaust mainfold was cracked, and told me it would be $750 to replace, I refused the repair, they charged me $75 for the evaluation.

- San Marcos, TX, USA

Heard excessive noise coming from engine. Investigation revealed that the exhaust header was cracked at the exhaust flange connecting the crossover pipe to the manifold.

- Colorado Springs, CO, USA

I have a 1999 Jeep Wrangler which was manufactured in Oct of 1998. My oem exhaust manifold had two cracks in it as of December of 2003, with the milage on the vehicle being roughly 42000. I replaced the manifold with an aftermarket manifold purchased from O'reilly auto parts in springfield, mo. Eleven months later, the aftermarket manifold cracked also. There is too much heat and pressure in the 4.0 engine for the manifolds to be able to handle, causing failure. Jeep dealerships replace hundreds daily, and are well aware of the engine problem, but also that the stock manifolds are made out of weak materials. Any muffler shop or tech will agree with this, as did 8 Jeep engineers at camp Jeep. I am currently going on my 3rd, and plan on changing to either a borla or banks header to try to solve the problem. Headman hedders has discontinued making a replacement for the Jeep because they aren't able to solve the problem, and borla agrees, but continues to warranty exchange those that come back cracked. The exhaust leaks penetrate the cab and can cause headaches and drowsiness after long periods of exposure. Gas milage is greatly reduced by this issue. I am looking for reimbursement of my aftermarket header if Jeep is unable to correct the issue or recall the manifolds.

- Ozarke, MO, USA

Experianced headaches, nausea, as well as audible knocking from under hood. My 1999 4.0 liter 6 cylinder was found to have broken exhaust manifold, leaking hot gasses and exhaust into engine compartment and passenger compartment. Dealership aware that there is problem with manifold, as have redesigned it and replacement cost in excess of $500 contacted Chrysler and filed complaint, told they area aware of problem, but will not stand behind it or issue recall. Local exhaust shop advised they do several per month with this defective exhaust manifold, both Wrangler and Cherokee between 1996 and 2000 model year. Exhaust was revised in 2000 because of problems, but Chrysler will not stand behind product denying the problem is a defect. Chyrsler should warranty this problem as they did with the 2.5 liter. Milage at time was only 39,000 when cracked.

- Grand Island, NE, USA

1)the vehicle failed the annual inspection - and I was advised the reason was "exhaust manifold". 2)I called the dealer - who thought my vehicle was a "2.5" which already has a recall on the exhaust manifold, but I have a "4.0" which currently does not. I asked what harm is being done if I do not get it fixed - and was advised that since there is a hole in the exhaust manifold, exhaust fumes are filling the cab (like the 2.5). I was at that time advised that there is no recall on this part. As it was explained to me, the part on the 2.5 is a bolt that attaches to the motor, and when it breaks, leaks exhaust into the cab; and on the 4.0 (which I believe is also a common problem), that there is a break in the base of the "Y" pipe, which also leaks exhaust into the cab. I called the manufacturer customer line 800.992.1997, I advised that I was aware that this was a serious problem, and that there is already a recall on a similar model; I was told that all they could do was "register the complaint". I asked "how does one go about a recall process" and was told it was involved and complicated, and I was directed to this site after pressing for satisfaction. I then asked "how many people have to die before you recall this part?", and the rep on the other end of the line giggled. I went on to ask that if there was a recall on this part would I be reimbursed for my expenditure, and I was advised that "yes", I would be reimbursed for having to pay for this repair. 3)because it is a dangerous condition, I am having the exhaust manifold replaced. I can make it available for inspection.

- Houston, TX, USA

A popping noise from the exhaust manifold was heard when consumer removed foot from gas pedal. During a state inspection the state inspector noticed a leak in the exhaust manifold. Consumer took vehicle to a dealership, who indicated this was a common problem with vehicles with a 4.0 liter engine.

- Dumfries, VA, USA

Consumer experienced headaches and dizziness for months due to an exhaust leak. The problem was discovered to be a cracked manifold. The consumer requested assistance, but was told only the 4 cylinder was being covered under warranty.

- Sandwich, IL, USA

Every manifold in Jeep Wrangler are faulty and crack leaving the cabins of Wrangler filling with carbon monoxide. This is a well known issues with Jeep Wrangler where the manifold is made with iron that does not expand and the welsing is sub par allowing for cracks which leak carbon monoxide.

- Little Elm, TX, USA

Manifold cracking on 1999 Jeep Wrangler, causing rough running condition and fumes inside cabin.

- Benwood, WV, USA

I have replaced the exhuast manifold twice because it has cracked above the Y connector at the pipe.now I will go with a borlla exhuast unit to see if this manufacturer defect can be corrected. Which I believe to be a defect in the motor mounts that are too week and allows the motor to lift too far and stress the pipe.

- Waterford, MI, USA

I love my 1999 Jeep Wrangler and have been very happy till now. My husband and I have owned many new cars over the years and this is the first time either one have heard of an exhaust manifold going bad. When having the manifold replaced we were told it has been redesigned and is different than the one replaced. It had cracked in several places, mainly at the welds. I fill since I never take it off road that this should not of happen. Not to mention it was very costly. I fill since this is a manufacturer problem I should be reversed for something like this.

- Troy, OH, USA

There is a crack in my exhaust manifold in my 1999 Jeep Wrangler. When I looked into the problem, I have found many people with the same complaint. I also learned from a diamler-chrylser dealer that they replace over 250 of these a day. And in 2000, they changed the part. This makes me think they realized it was defective and did nothing to the victims that had the defective part.

- Wellesley, MA, USA

1999 Jeep Wrangler 6 cycl. Has been to the dealership on multiple visits. Loss of power during highway driving. After replacing the fuel pump, radiator, and performing an additional tune-up but problem is still unresolved. Now find that there is a crack in the intake manifold and the exhaust manifold has completely cracked.

- Ronkonkoma, NY, USA

First heard a problem with the exhaust system just prior to the easter holiday 2002 and took it to the dealership to be investigated after the holiday weekend. I was told the was a crack in the exhaust manifold and the vehicle was one day out of warranty (due to the holiday weekend). After considerable debate, the dealership agreed to repair the vehicle for a $150 deductible. Now a year and a half later the exact same issue has arisen and the factory repair is only warranted for 12 months/12,000 miles. After an exchange of 4 emails with daimler/Chrysler they continue to tell me there is nothing they can do and I am liable for the full repair cost.

- Las Vegas, NV, USA

Many Jeep Wrangler built before 2001 have a defective manifold that cracks, causing exhaust problems. This is the reason Jeep completely redesigned the manifold in the newer models. They have yet to send out a recall to fix this problem. When I first noticed the loud noise resulting from the cracked manifold, my car had approximately 37,000 miles on it. Not high mileage by any means. The main concern I have with this problem is the health hazard it poses to the driver. The section of the Wrangler where the cracked manifold is located is underneath the front of the car, where exhaust fumes leaking from it seep up into the cabin very easily, especially when stopped at lights or in heavy traffic. I believe the manufacturers of Jeep are very aware of this problem but don't care to do anything about it.

- Frisco, TX, USA

Small crack developed in exhust manifold, causing ticking noise and lowered fuel economy.

- Marysville, MI, USA

The exhaust manifold cracked in three different places and caused the vehicle to misfire and stall. An independent shop stated that the manifold cracked because it was not properly supported. The dealer was notified but stated there was nothing they could do.

- Mission, KS, USA

Exhaust manifold cracked in two places. Poor design due to the inability to expand and contract due to thermal expansion (in an exhaust manifold!!!). exhaust fumes entering cabin while driving.

- Townville, SC, USA